Weatherproof electrical enclosure with reinforcement

ABSTRACT

The present disclosure provides descriptions of electrical box assemblies for supporting heavy fixtures, such as ceiling fans, and facilitating electrical connections to the fixtures. The electrical box assembly includes an electrical box that allows a connection between the box and electrical conduits and a connection, e.g., a weatherproof connection, with a housing of the fixture. The box has an open front face to house electrical connections between the fixture and wires supplying electrical power to the box via the conduits. The box has a bottom wall and an open front face. A reinforcement member fits within the electrical box and includes a panel shaped to conform to at least a portion of the bottom wall and one or more standoffs extending toward the open front face of the box. When the reinforcement member is positioned within the box, mounting holes in the bottom wall of the box and reinforcement member are aligned to allow the box to be attached to a building structure.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present disclosure is based on and claims benefit from co-pendingU.S. Provisional Application Ser. No. 62/528,659 filed Jul. 5, 2017entitled “Weatherproof Electrical Enclosure with Reinforcement” and fromco-pending U.S. Provisional Application Ser. No. 62/646,089 filed Mar.21, 2018 entitled “Weatherproof Electrical Enclosure with Reinforcement”the contents of both applications are incorporated herein in theirentirety by reference.

BACKGROUND Field

The present disclosure relates generally to electrical boxes. Moreparticularly the present disclosure relates to electrical boxes made ofnon-conductive materials and a reinforcement member to support ceilingfans and other heavy fixtures.

Description of the Related Art

Connection of ceiling-mounted electrical fixtures, such as ceiling fans,chandeliers and the like, is typically accomplished by installing anelectrical box to a structural member within the ceiling, connectingelectrical conduits to the box, mechanically attaching the fixture tothe electrical box, and electrically connecting the fixture to wiresrunning through the conduit. The box provides a means for connectionwith the conduit, the ceiling and the fixture, and supports the weightof the fixture and securely holds the fixture in place during use. Inthe case of ceiling fans, the electrical box may need to support the fanagainst torque generated as the fan is rotated.

Electrical fixtures may be designed to be mounted in outdoor and/orindoor environments. In outdoor environments, such fixtures may includea weatherproof housing that limits moisture, dust, pests, and otheroutdoor hazards from the mechanism and circuitry of the device. Toreliably provide connection to such devices, the electrical box itselfmay need to be weatherproof.

Ceiling fans are relatively heavy, compared with other electricalfixtures, such as lighting fixtures. In addition, ceiling fans generatetorque. To support the additional weight of the ceiling fan and tosecurely support the ceiling fan, the electrical box needs to havesufficient mechanical strength. Plastic electrical boxes constructedfrom molded polymers may lack sufficient strength to support heavyelectrical fixtures. Strength may be provided by constructing theelectrical box from metal, such as steel or heavy gauge aluminum. Tocreate a weatherproof metal electrical box, joints between metal panels,for example, joints between edges of folded sections of the box, must besealed. Likewise, connections to conduits may need to include sealingstructures, such as O-rings, to make them weatherproof. Forming anelectrical box from metal and sealing it may be complex and moreexpensive than using plastic electrical boxes.

SUMMARY

The present disclosure provides descriptions of embodiments for ceilingmounted electrical box assemblies used to support relatively heavyelectrical fixtures, such as ceiling fans. The present disclosureprovides descriptions of ceiling fan kits that incorporate an electricalbox assembly of the present disclosure and a ceiling fan. The electricalbox assemblies of the present disclosure are made of a non-conductiveelectrical box and a reinforcement member that provides mechanicalstrength to support the weight of the electrical fixture and to resisttorque or other forces generated when the electrical fixture isoperated.

In one embodiment, the electrical box assembly includes an electricalbox and a reinforcement member. The electrical box has a bottom wallwith a mounting zone and an open front face. The reinforcement memberhas a panel and one or more standoffs extending from the panel. Thepanel is shaped to conform to at least a portion of the bottom wall ofthe box so that the panel can be positioned within the electrical boxadjacent the bottom wall. The one or more standoffs extend toward thefront face of the box and include at least one connecting holeconfigured to receive a fastener of the fixture.

In another embodiment, the electrical box assembly includes anelectrical box, a reinforcement member and a shroud. The electrical boxhas a bottom wall with a mounting zone and an open front face. Thereinforcement member has a panel and one or more standoffs extendingfrom the panel. The panel is shaped to conform to at least a portion ofthe bottom wall of the box so that the panel can be positioned withinthe electrical box adjacent the bottom wall. The one or more standoffsextend toward the front face of the box and include at least oneconnecting hole configured to receive a fastener of the fixture. Theshroud is configured to be connected with the front face of the box.More specifically, the electrical box may include a first mating surfaceon the open front face and the shroud may include a corresponding secondmating surface such that when joined the first and second matingsurfaces create a weatherproof engagement.

In one embodiment, a ceiling fan kit includes an electrical box assemblyand a ceiling fan assembly. The electrical box assembly includes anelectrical box and a reinforcement member. The electrical box has abottom wall with a mounting zone and an open front face. Thereinforcement member has a panel and one or more standoffs extendingfrom the panel. The panel is shaped to conform to at least a portion ofthe bottom wall of the box so that the panel can be positioned withinthe electrical box adjacent the bottom wall. The one or more standoffsextend toward the front face of the box and include at least oneconnecting hole configured to receive a fastener of the fixture. Theceiling fan assembly includes a ceiling fan and a ceiling fan mountingbracket.

BRIEF DESCRIPTION OF THE DRAWINGS

The figures depict embodiments for purposes of illustration only. Oneskilled in the art will readily recognize from the following descriptionthat alternative embodiments of the structures illustrated herein may beemployed without departing from the principles described herein,wherein:

FIG. 1 is an exploded perspective view of a ceiling fan engaged with anelectrical box assembly according to an exemplary embodiment of thedisclosure;

FIG. 2a is an upper perspective view with parts separated of theelectrical box assembly of FIG. 1, illustrating an electrical box, areinforcement member and an optional shroud;

FIGS. 2b is a lower perspective view of the electrical box assembly ofFIG. 1, illustrating the electrical box, reinforcement member andoptional shroud;

FIG. 2c is a detailed perspective view of another exemplary embodimentof a portion of the electrical box of FIGS. 2a and 2 b;

FIG. 3a is detailed perspective view of a portion of the electrical boxof FIGS. 2a and 2 b;

FIG. 3b is a detailed perspective view of a portion of the shroud ofFIGS. 2a and 2 b;

FIG. 4 is a partial cross-sectional view of an engagement between theelectrical box and shroud of FIGS. 2a and 2 b;

FIG. 5a is a lower perspective view of another exemplary embodiment ofan electrical box assembly according to the present disclosure;

FIG. 5b is a detailed perspective view of a portion of the electricalbox assembly of FIG. 5 a;

FIG. 5c is a detailed perspective view of another exemplary embodimentof the portion of the electrical box assembly of FIG. 5 b;

FIG. 6 is another exemplary embodiment of an electrical box assemblyaccording to the present disclosure;

FIG. 7 is a perspective view of the electrical box and reinforcementmember of the electrical box assembly of FIG. 1 secured to a ceilingjoist;

FIG. 8 is a perspective view with parts separated of another exemplaryembodiment of electrical box assembly according to the presentdisclosure, illustrating the electrical box assembly attached to aceiling joist, an electrical conduit attached to the electrical boxassembly and a ceiling fan positioned to be attached to the electricalbox assembly;

FIG. 9 is a perspective view of the electrical box assembly of FIG. 8,illustrating an interior of another exemplary embodiment of anelectrical box having a reinforcement member positioned within theelectrical box;

FIG. 10 is a lower perspective view with parts separated of theelectrical box assembly of FIG. 9, illustrating the reinforcement memberthat fits within the electrical box and an optional shroud;

FIG. 11 is a perspective view of the electrical box of FIG. 10;

FIG. 12 is a perspective view of another exemplary embodiment of anelectrical box according to the present disclosure;

FIG. 13 is a perspective view of the reinforcement member of FIG. 10;

FIG. 14 is an upper perspective view of the electrical box assembly ofFIG. 9, illustrating the optional shroud attached to the electrical box;

FIG. 15 is a top plan view of the electrical box assembly of FIG. 8connected to a building structure and illustrating a mounting zone ofthe electrical box and lag screws in the mounting zone securing theelectrical box assembly to the building structure; and

FIG. 16 is a top plan view of the electrical box assembly connected to abuilding structure similar to FIG. 15 and illustrating the mounting zonerotated about forty-five degrees and lag screws in the mounting zonesecuring the electrical box assembly to the building structure.

DETAILED DESCRIPTION

The present disclosure provides descriptions of embodiments for aweatherproof electrical box assembly having an electrical box and areinforcement member for supporting and facilitating electricalconnections to ceiling mounted electrical fixtures. The electrical boxassemblies according to the present disclosure may be referred to hereinas the “box assembly” in the singular and the “box assemblies” in theplural. The electrical box may be referred to as the “box” in thesingular and the “boxes” in the plural. The electrical fixturescontemplated by the present disclosure include ceiling fans, chandeliersand other electrical fixtures that are heavy and/or require additionalstructural strength to support the electrical fixture when installed.The electrical fixtures may be referred to herein as the “fixture” inthe singular and as the “fixtures” in the plural. This specification andthe accompanying drawings are to be regarded in an illustrative senserather than a restrictive sense. Various modifications may be madethereto without departing from the spirit and scope of the presentdisclosure.

Referring to FIGS. 1, 2 a and 2 b, a fixture 102 is connected by abracket 104 with an electrical box assembly 100 according to anembodiment of the present disclosure. The box assembly 100 includes anelectrical box 110, e.g., a molded polymer box, a reinforcement member112, and an optional shroud 114. Lag screws 116 are used to connect thebox assembly 100 with a building structure, as will be described below.Screws 118 connect the shroud 114 with the electrical box 110. The boxassembly 100 is secured to a building structure, e.g., a ceiling joist10 seen in FIGS. 7 and 8, to fix the box 110 in position relative to thebuilding structure, to support the fixture 102 and to facilitateelectrical connections to the fixture.

The box 110 includes conduit openings 120 used to create a weatherproofconnection between the box 110 and an electrical conduit 12, seen inFIG. 8. The conduit openings 120 may be provided at various locations onthe box 110 to facilitate convenient connection with conduits in anumber of directions including through the upper surface of the box 110.As shown in FIG. 2b , the face 121 of the box 110 is open, allowing aninstaller access to the inside of the box 110 during installation.

Conduit openings 120 may be provided with removable plugs 119 that formweatherproof closures for the openings. An installer selects whichconduit openings 120 are most conveniently located with regard to theconduits being connected with the box and removes the plugs only fromthose openings. The remaining plugs 119 maintain a weatherproofconnection with the box 110. According to the embodiment shown in FIGS.2a and 2b , openings 120 are provided with threads along their innercircumference. The threads connect either plugs 119 or conduits with thebox 110. A screwdriver slot 117 is provided on the surface of the plug119 so that the installer can unscrew the plug from the box 110.According to another embodiment, openings 120 have a smooth innercircumference and plugs 119 form a weatherproof frictional engagementwith the openings 120. According to this exemplary embodiment, conduitsmay likewise form a frictional engagement with openings 120 and/orconduits may be bonded with openings 120 with an adhesive.

According to another exemplary embodiment shown in FIG. 2c , instead ofplugs 119, the openings 120 are each provided with a knock-out panel115. The person installing the box 110 can remove the knock-out panels115 at locations convenient to connect the box 110 with a conduit. Otherknock-out panels are left intact to provide a weatherproof enclosure.

According to one embodiment, the box 110 is formed from a moldablenon-conductive or electrically insulating material. A non-limitingexample of a moldable non-conductive or electrically insulating materialis plastic. Non-limiting examples of suitable plastic materials includemoldable polymer resin, such as polyvinyl chloride (PVC), nylon,polyethylene terephthalate (PET), polybutylene terephthalate (PBT), andthe like.

As shown in FIGS. 2a and 2b , an exemplary embodiment of a reinforcementmember according to the present disclosure is shown. The reinforcementmember 112 includes a panel 122 and standoffs 124 extending from thepanel. The panel 122 may be made of a metal or metal alloy, such assteel, aluminum, copper, brass, bronze, and the like. According to oneembodiment, the panel 122 is formed from 0.045″ cold-rolled steel. Thepanel 122 may include ribs 126 to provide stiffness to the panel 122,and mounting holes used when mounting the box 110 to a buildingstructure. The mounting holes 128 are provided at the ends of the panel122. According to one embodiment, panel 122 is stamped from a sheet ofmaterial and the ribs 126 and mounting holes 128 are formed as part ofthe stamping process.

Continuing to refer to FIGS. 2a and 2b , the standoffs 124 may be madeof a metal or metal alloy, such as steel, aluminum, copper, brass,bronze, and the like and may be made from the same material as the panel122 or from a different material. According to one embodiment, thestandoffs 124 are connected with the panel 122 by welding, riveting, orpress fitting. The standoffs 124 are hollow and are threaded along theirinner surface. The standoffs 124 are provided to facilitate the transferof the load of a fixture mounted to the box 110 to the reinforcementmember 112. The standoffs 124 also provide rigidity to the standoffholes through which the standoffs are inserted. More specifically, thebox 110 includes standoff holes 130 extending from the upper surface ofthe box 110, seen in FIG. 2a , through bosses 131 to the face 121 of thebox, seen in FIG. 2b . The standoff holes 130 are positioned on the box110 to align with standoffs 124 extending from the panel 122. In anexemplary embodiment, the diameter of the standoff holes 130 forms aninterference fit with the outer surface of the standoffs 124 so thatwhen the standoffs 124 are inserted into the standoff holes 130, thereinforcement member 112 is removably fixed to the box 110. With thisinterference fit, the standoffs 124 also provide the additionalstructural rigidity to the bosses 131 as noted above. The box 110 alsoincludes mounting holes 132 that align with mounting holes 128 of thereinforcement member 112 when the standoffs 124 are inserted into thestandoff holes 130.

Continuing to refer to FIG. 2a , the box 110 includes a debossed area134 on its upper surface that is shaped to conform with the panel 122 ofthe reinforcement member 112. When the reinforcement member 112 isconnected with the box 110, the panel 122 fits within the debossed area134 so that the upper surface of the panel 122 is flush with the uppersurface of the box 110. The debossed area 134 may include grooves 136shaped to accommodate ribs 126 formed in the panel 122. Thisconfiguration allows the box assembly 100 to be mounted with its uppersurface flush to a building structure, such as the underside of aceiling joist. When the reinforcement member 112 is fitted onto the box110, the mounting holes 128 on the panel 122 and the mounting holes 132on the box 110 are aligned. Lag screws 116 can then pass though thealigned mounting holes and engage with the building structure that willsupport the fixture, such as fan 102, seen in FIG. 1.

As shown in FIG. 2b , the box 110 may also include shroud mounting holes140 formed in bosses 141. According to one embodiment, the ends of thebosses 141 are flush with the face 121 of the box 110. In the exemplaryembodiment shown, the shroud 114 forms an annular ring with an opening142. The opening is shaped to correspond with the open face 121 of thebox 110. Arranged around the opening 142 are bracket mount holes 144 andshroud mount holes 146. As shown in FIG. 2a , a plurality of ridges 148extend partially around opening 142. The ridges 148 are separated bygaps 150 and 152 corresponding to holes 144 and 146, respectively.According to one embodiment, the gaps 150 and 152 are of differentlengths along the circumference of opening 142. The present disclosurealso contemplates that the gaps may have the same length.

Referring to FIG. 4, a cross-section showing the joint between theshroud 114 and the box 110 when the shroud and box are mounted togetheris shown. The ridge 148 of the shroud 114 engages with a shoulder 160along the inner circumference of the face 121 of the box 110. Engagementof the rib 148 and shoulder 160 provides a weatherproof interlockingengagement between the shroud 114 and box 110. As shown in FIGS. 2a and2b , the gaps 152 are positioned adjacent bosses 141 when the shroud 114is joined with the box 110. As shown in FIGS. 3a and 3b , each gap 152is sized to correspond to the width of a boss 141 in the circumferentialdirection around the face 121 of the box 110. Likewise, the gaps 150 arepositioned adjacent bosses 131. Each gap 150 may be sized to correspondwith the bosses 131. According to one embodiment, the gaps 150 arenarrower than the widths in the circumferential direction of the bosses131. Thus, in order to engage the shroud 114 with the box 110, the gaps150 should be aligned with bosses 131 and the gaps 152 should be alignedwith bosses 141. This arrangement creates a clocking engagement, whereinthe shroud 114 can be attached to the box 110 when the angulararrangement between them is such that shroud mounting holes 146 alignwith shroud mounting holes 140 and standoff holes 144 align with thestandoff holes 130. Referring to FIG. 3a , a detailed view of a portionof the box 110 is shown. More specifically, a boss 131 with standoffhole 130, and a boss 141 with a shroud mounting hole 140 are shown.Referring to FIG. 3b , a detailed view of a portion of the shroud 114 isshown. More specifically, a shroud mounting hole 146 with ridges 148separated by a gap 152 are shown. As shown in FIGS. 2a and 2b , screws118 can fit through the shroud mounting holes 146 of the shroud 114 andengage with shroud mounting holes 140 of the box 110. The screws 118 maybe self-threading screws that cut into the surface of shroud mountingholes 140. According to one embodiment, the screws 118 are #6-32 or#8-32 self-tapping screws. Alternatively, a threaded surface is providedon the inside of shroud mounting holes 140 and threaded screws 118engage with that threaded surface. When installed on the box 110, theshroud 114 forms a flat surface extending outward from the box 110.Engagement of fan housing 103, seen in FIG. 1, with the surface ofshroud 114 forms a decorative cover around the box 110 and aweatherproof connection between the fixture, here fan 102, and the boxassembly 100.

As shown in FIG. 1, bracket 104 can be used to connect a fixture, here aceiling fan, to the box assembly 100. The bracket 104, which istypically provided with the ceiling fan, includes mounting holes 170.The mounting holes 170 are separated by the same distance as thestandoff holes 130 of the box 110. Screws 172, used to secure thebracket 104 to the standoffs 124, fit through the mounting holes 170 andengage with the standoffs 124 that are disposed within the standoffholes 130. Threading on the inner surface of the standoffs 124corresponds to the threading of the screws 172. According to oneembodiment, the screws 172 are #10-24 machine screws.

Installation of a fan 102 using the electrical box assembly 100according to one embodiment of the disclosure is as follows. Aninstaller inserts the standoffs 124 of the reinforcement member 112 intothe standoff holes 130, as shown in FIGS. 2a and 2b . The installerselects which openings 120, seen in FIG. 2c , of the box 110 aresuitably positioned in relation to electrical conduits to which the boxassembly 100 will be connected. The installer removes the appropriateplugs 119, if installed, or knockouts 115 to allow connection of theconduits to the box 110. The installer positions the box 110 with thereinforcement member 112 against the structure to which the fixture,here the ceiling fan 102, will be mechanically connected. As notedabove, the structure the box 110 may be mounted to any suitable buildingstructure, such as for example, the underside of a ceiling joist as seenin FIG. 7. The installer inserts the lag screws 116 through mountingholes 132 of box 110 and the mounting holes 128 of the reinforcementmember 112 and drives the lag screws into the building structuresecuring the box 110 and the reinforcement member 112 to the buildingstructure. The installer connects one or more conduits to the selectedopenings 120 in the box 110. Connection may be by way of threadedengagement of the conduit connectors with threaded surfaces of theopenings 120, by friction fitting conduits into the openings 120, and/orby application of an adhesive to bond ends of conduits within theopenings 120. The installer positions shroud 114 against the face 121 ofbox 110 and rotationally aligns the shroud 114 so that gaps 152 arealigned with bosses 141 and holes 146 of the shroud align with holes 140of box 110. The installer affixes shroud 114 to box 110 using screws118. The installer then connects the ceiling fan bracket 104 to the boxassembly 100 by inserting screws 172 through mounting holes 170 in thebracket 104 and threading the screws into the standoffs 124 positionedwithin the standoff holes 130 of the box 110. The fixture, here the fan102, can then be mounted to the bracket 104 according to methods knownin the art.

According to another exemplary embodiment of the present disclosure, theshroud 114 may be omitted. Such a configuration may be used where thebox assembly 100 is positioned so that the face 121 of the box 110 isflush with or recessed within a ceiling of a building. In thisconfiguration, the bracket 104 is mounted to the standoffs 124 withinstandoff holes 130 by the screws 172 with the bracket 104 in directcontact with the face 121 of the box 110. A weatherproof connection ismade between the fan housing 103 and the ceiling of the building.

Referring to FIGS. 5a and 5b , another exemplary embodiment of the boxassembly 200 according to the present disclosure is shown. In thisexemplary embodiment, the box 210 is provided with standoff holes 230extending through bosses 231. According to this exemplary embodiment, tocreate a weatherproof connection with an installed fixture, a housing ofthe fixture would engage with the ceiling or other surface of thebuilding. However, the shroud described above may be used with this boxassembly. According to one embodiment, an insert, such as a metalinsert, may be molded into the bosses 231 of the box 210 to form thestandoff holes 230 to provide additional mechanical strength to thebosses. Lag screws 218 can then be passed through the standoff holes 230so that the lag screws extend from the front of the box 210 through theback surface of box 210, as shown in FIG. 5a . When the box assembly issecured to a building structure, the lag screws 218 engage with thebuilding structure, for example, a ceiling joist, to secure the boxassembly to the building. In this embodiment, the lag screws 218 mayalso pass through and engage with the mounting holes 170 on the fanbracket 104 or other connecting feature on the fixture to be installed,to connect the fixture to the building structure. FIG. 5c shows anotherexemplary embodiment of the box assembly 200 according to the presentdisclosure, where metal inserts 220 are provided within the standoffholes 230. The inserts 220 provide additional rigidity to the bosses 231so that the lag screws 218 can support the fixture.

FIG. 6 shows another exemplary embodiment of the box assembly accordingto the present disclosure. In this embodiment, the box assembly 300,which is similar to the box assembly of FIGS. 5a-c , with lag screws 318extending through box 310 and out the upper surface of the box to engagewith a building structure. In this embodiment, a shroud 314 is fitted tothe face of box 310 to provide a weatherproof engagement with thehousing of a fan.

Referring to FIGS. 8-15, another exemplary embodiment of a box assemblyaccording to the present disclosure is shown. Similar to the abovedescribed embodiments, a fixture 102 is connected by a bracket 104 withthe electrical box assembly 400 according to this exemplary embodiment.The box assembly 400 includes a box 410, e.g., a molded polymer box, areinforcement member 430 configured to be positioned within the box 410,and an optional shroud 460, as seen in FIG. 10. Lag screws 116, seen inFIG. 10, can pass through holes in the box 410 and reinforcement member430 and are provided to connect the box assembly 400 to a buildingstructure 10, as will be described below. Screws 118, seen in FIG. 10,connect the shroud 460 to the electrical box 410. Generally, the boxassembly 400 is secured to a building structure 10, e.g., a ceilingjoist seen in FIG. 8, to fix the position of the electrical box 410relative to the building structure, to support the fixture 102 and tofacilitate electrical connections to the fixture.

As shown in FIGS. 9 and 11, the box 410 includes a bottom wall 412 and aface 414 that is open allowing an installer access to the inside of thebox 410 during installation. The box 410 also includes one or moreconduit openings 416 used to create a weatherproof connection betweenthe box 110 and an electrical conduit 12, seen in FIG. 8. The conduitopenings 416 may be provided at various locations on the box 410 tofacilitate convenient connection with conduits in a number ofdirections. The conduit openings 416 are similar to the embodiments ofconduit openings 120 described above and for ease of description are notrepeated. The bottom wall 412 of the box 410 includes mounting holes 418used when securing the box assembly 400 to a building structure. Themounting holes 418 are preferably positioned on opposite sides of aconduit opening 416 in the bottom wall of the box 410 within a boxmounting zone, which is generally referenced in FIGS. 15 and 16.Generally, the box mounting zone is for reference and has a width thatat least covers the width of a typical building structure joist, such asa ceiling joist. For general reference, the width of a typical 2″×10″ceiling joist is from about 1½″ and about 2″. The length of the boxmounting zone can extend from one side of the box an opposite side ofthe box 410, or any length that is less than extending from one side ofthe box an opposite side of the box. By positioning the mounting holes418 in the box mounting zone, the box 410 can be rotated a predeterminednumber of degrees while still being positioned so that the lag screws116 can grip the building structure 10. The predetermined number ofdegrees depends upon the width of the building structure 10 the box 410will be secured to. As a non-limiting example, if the building structure10 is a 2″×10″ ceiling joist, the predetermined number of degrees wouldbe about 45 degrees. More specifically, if the box were set in a firstposition, as shown in FIG. 15, the lag screws 116 would be in a positionto grip the 2″×10″ ceiling joist, and if the box 410 were rotated 45degrees to a second position, as shown in FIG. 16, the lag screws 116would still be in a position to grip the 2″×10″ ceiling joist.

Continuing to refer to FIGS. 9 and 11, the conduit opening 416 in thebottom wall 411 has a raised wall 416 a extending into the interior ofthe box 410 and a pair of ribs 420 are positioned around the perimeterof the raised wall 416 a of the conduit opening 416 as shown. The ribs420 are used to provide a key for mounting the reinforcement member 430as described below. In another exemplary embodiment, shown in FIG. 12,the bottom wall 412 of the box 410 may have a boss 417 instead of theconduit opening 416. The boss 417 has a raised wall 417 a extending intothe interior of the box 410 and a pair of ribs 420 are positioned aroundthe perimeter of the raised wall 417 a of the boss 417 as shown. Asnoted above, the ribs 420 are used to provide a key for mounting thereinforcement member 430 as described below. The box 410 may alsoinclude shroud mounting holes 422 formed in bosses 424. According to oneembodiment, the ends of the bosses 424 are flush with the face 414 ofthe box 110.

According to an exemplary embodiment, the box 410 is formed from amoldable non-conductive or electrically insulating material. Anon-limiting example of a moldable non-conductive or electricallyinsulating material is plastic. Non-limiting examples of suitableplastic materials include moldable polymer resin, such as polyvinylchloride (PVC), nylon, polyethylene terephthalate (PET), polybutyleneterephthalate (PBT), and the like.

Referring now to FIGS. 10 and 13, another exemplary embodiment of areinforcement member according to the present disclosure is shown. Thereinforcement member 430 includes panel 432 and one or more standoffs434 extending from the panel. In the exemplary embodiment shown, thepanel 432 is circular in shape to conform to the circular shape of thebox 410. However, the present disclosure contemplates panels 432 havingdifferent shapes including square and rectangular shapes to conform tosquare and rectangular boxes, respectively. The panel 432 may be made ofa metal or metal alloy, such as steel, aluminum, copper, brass, bronze,and the like. According to one embodiment, the panel 432 is formed from0.045″ cold-rolled steel. The panel 432 includes an opening 436 having adiameter sufficient to receive the conduit opening 416 in the bottomwall 412 of the box 410. Around the perimeter of the opening 436 are oneor more projections 438 that are preferably spaced apart as shown inFIG. 13. The projections 438 are provided to engage the raised wall 416a of the conduit opening 416 to temporarily hold the reinforcementmember 430 in position when mounting the box assembly 400 to a buildingstructure. Around the perimeter of the opening 436 are one or more keyslots 440 that are configured to receive the ribs 420 on the raised wall416 a of the conduit opening 416 in the bottom wall 412 of the box 410.By aligning the ribs 420 with the slots 440 the reinforcement member 430can be properly aligned within the box 410 as described below. It isnoted that the boss 417, seen in FIG. 12, in the bottom wall 412 of thebox 410 may be substituted for the conduit opening 416 in the bottomwall of the box with similar results as described above.

The panel 432 may include a raised surface or rib 442 surrounding theopening 436 and extending along the standoffs 434, as shown in FIG. 13.The raised surface or rib 442 provides stiffness to the reinforcementmember 430. The raised surface or rib 442 may include a flat top surface442 a that includes mounting holes 444 that are used when mounting thebox 410 to a building structure. The mounting holes 444 are positionedon the rib 442 so that they align with the mounting holes 418 in thebottom wall 412 of the box 410 when the reinforcement member 430 ispositioned within the box 410 and the slots 440 of the panel 432 arealigned with the ribs 420 on the conduit opening 416. Around themounting holes 444 in the rib 442, the rib expands to form a gasketcradle 445. The gasket cradles 445 are configured to receive a sealinggasket or washer as described below. The rib 442 may include a groundinghole 446 with a grounding screw 448, seen in FIG. 10, used to ground thereinforcement member 430. The grounding screw 448 may be self-threadingscrew that cuts into the surface of the grounding hole 448. According toone embodiment, the grounding screw 448 is a #8-32 self-tapping screwcolor coded green.

According to one embodiment, the panel 432 may be stamped from a sheetof material and the mounting holes 444 can be formed as part of thestamping process. The rib 442 can also be formed as part of the stampingprocess.

Continuing to refer to FIGS. 10 and 13, the standoffs 434 may be made ofa metal or metal alloy, such as steel, aluminum, copper, brass, bronze,and the like and may be made from the same material as the panel 432 orfrom a different material. In one exemplary embodiment, the standoffs434 are integrally formed with the panel 432 to form a monolithicstructure. In another exemplary embodiment the standoffs 434 can beconnected to the panel 432 by mechanical fasteners, such as welding,riveting, or screwing the standoffs 434 to the panel 432, or usingadhesive fasteners. The standoffs 434 include an arm 434 a extendingfrom the panel 432 and a connecting leg 434 b extending substantiallyperpendicular to the arm 434 a. The standoffs 434 are provided tofacilitate the transfer of the load of a fixture to be mounted to thebox 410 through the reinforcement member 430 and ultimately to thebuilding structure the box assembly 400 is secured to. The connectinglegs 434 b of the standoffs 434 include connecting holes 450 and 452that are used to mount the fixture to the reinforcement member 430 andthus to the box 410. The connecting holes 450 are threaded andconfigured to receive one size screw used to mount the fixture to thereinforcement member 430, such as a #8-32 machine screw, and connectingholes 452 are configured to receive another size screw used to mount thefixture to the reinforcement member 430, such as a #10-24 machine screw.It is noted that the connecting holes can be configured to receive anytype of screws.

Referring again to FIG. 10, the shroud 460 forms an annular ring with anopening 462. The opening 462 is shaped to correspond with the open face414 of the box 410. Arranged around the opening 462 are shroud mountholes 464 that are positioned and configured to align with the shroudmounting holes 422 formed in bosses 424 in box 410. As noted above, thescrews 118 are used to connect the shroud 460 to the shroud mountingholes 422.

As shown in FIG. 8, bracket 104 can be used to connect a fixture 102,here a ceiling fan, to the box assembly 400. The bracket 104, which istypically provided with the ceiling fan, includes mounting holes 170.The mounting holes 170 are separated by the same distance as theconnecting holes 450 or 452 of the reinforcement member 430 of the boxassembly 400. Screws 172, used to secure the bracket 104 to theconnecting holes 450 or 452, fit through the mounting holes 170 andengage with the connecting holes 450 or 452 that are disposed in theconnecting leg 434 b of the reinforcement member 434. The connector hole450 or 452 threading corresponds to the threading of the screws 172.According to one embodiment, the screws 172 can be, for example, #10-24machine screws.

Referring to FIGS. 8 and 10, an exemplary method for installing theelectrical box assembly 400 and a fixture 102, which in this example isa ceiling fan, according to the present disclosure is as follows. Aninstaller positions a gasket 470 into each gasket cradle 445 in thereinforcement member 430 so that the gaskets 470 are aligned with themounting holes 44 in the reinforcement member. The installer inserts thereinforcement member 430 and gaskets 470 into the box 410 so that theribs 420 on the conduit opening 416 on the bottom wall 412 of the box410 are received in slots 440 of the panel 432. At this point, theprotrusions 438 of the opening 436 in the panel 432 engage the raisedwall 416 a of the conduit opening 416 to temporarily hold thereinforcement member 430 in position relative to the box 410 allowingthe installer time to secure the box assembly 400 to the buildingstructure 10. The installer selects which conduit openings 416 of thebox 410 are suitably positioned in relation to electrical conduits towhich the box assembly 400 will be connected. The installer removes theappropriate plugs or knockouts to allow connection of the conduit orconduits 12 to the box 410, as seen in FIG. 8. The installer positionsthe box 410 with the reinforcement member 430 against the buildingstructure 10 to which the fixture 102 will be mechanically connected. Asnoted above, the building structure to which the box 410 may be mountedto may be any suitable building structure 10, such as for example, aceiling joist. The installer inserts the lag screws 116 through mountingholes 444 of the reinforcement member 430 and the mounting holes 418 ofthe box 410, seen in FIGS. 9, 11 and 14, and drives the lag screws intothe building structure 10 securing the box 410 and the reinforcementmember 430 to the building structure. At this point, the gaskets 470,which are used in weatherproof applications, seal the mounting hole 418in the box 410 and the lag screw 116.

The installer then connects one or more conduits to the selected conduitopenings 416 in the box 410. Connection of the conduit 12 to the conduitopenings 416 may be by way of threaded engagement of conventionalconduit connectors (not shown) with threaded surfaces of the conduitopenings 416, by friction fitting conduits into the conduit openings416, and/or by application of an adhesive to bond ends of conduitswithin the conduit openings 416. If the optional shroud is to be used,the installer positions the shroud 460 against the face 414 of the box410 and aligns the shroud mounting holes 464 of the shroud 460 with theshroud mounting holes 422 in bosses 424 in the box 410. The installeraffixes the shroud 460 to box 410 using screws 118. The installer thenconnects the ceiling fan bracket 104 to the reinforcement member 430 byinserting screws 172 through connecting holes 450 or 452 in connectingleg 434 b of the reinforcement member 430. The fixture 102, here theceiling fan, can then be mounted to the bracket 104 and the electricalconnections made to the ceiling fan according to methods known in theart.

While illustrative embodiments of the present disclosure have beendescribed and illustrated above, it should be understood that theseembodiments are exemplary and are not to be considered as limiting.Additions, deletions, substitutions, and other modifications can be madewithout departing from the spirit or scope of the present disclosure.Accordingly, the present disclosure is not to be considered as limitedby the foregoing description.

What is claimed is:
 1. An electrical box assembly for supporting anelectrical fixture and facilitating electrical connections to theelectrical fixture, the electrical box assembly comprising: anelectrical box having a bottom wall and an open front face; and areinforcement member having a panel and one or more standoffs extendingfrom the panel, the panel being shaped to conform to at least a portionof the bottom wall of the box so that the panel can be positioned withinthe electrical box adjacent the bottom wall, and the one or morestandoffs extend toward the front face of the box and include at leastone connecting hole configured to receive a fastener of the fixture. 2.The electrical box assembly according to claim 1, wherein the bottomwall of the electrical box includes a mounting zone having a pluralityof box mounting holes.
 3. The electrical box assembly according to claim2, wherein the panel has a plurality of panel mounting holes that arepositioned to align with the box mounting holes such that one boxmounting hole aligns with one panel mounting hole when the panel ispositioned within the electrical box adjacent the bottom wall.
 4. Theelectrical box assembly according to claim 1, wherein the box is formedfrom a moldable non-conductive material.
 5. The electrical box assemblyaccording to claim 4, wherein the moldable non-conductive materialcomprises a plastic material.
 6. The electrical box assembly accordingto claim 5, wherein the plastic material comprises a moldable polymerresin.
 7. The electrical box assembly according to claim 1, wherein thereinforcement member is formed from a metal or metal alloy.
 8. Theelectrical box assembly according to claim 1, further comprising ashroud, the shroud being configured to be connected with the front faceof the box.
 9. The electrical box assembly according to claim 8, whereinthe electrical box comprises a first mating surface on the open frontface and the shroud comprises a corresponding second mating surface, andwherein when joined the first and second mating surfaces create aweatherproof engagement.
 10. The electrical box assembly according toclaim 1, wherein the one or more standoffs comprise an arm extendingfrom the panel and a connecting leg substantially perpendicular to thearm and having the at least one connecting hole.
 11. The electrical boxassembly according to claim 1, wherein the box comprises one or moreconduit openings.
 12. An electrical box assembly comprising: anelectrical box having a bottom wall and an open front face; areinforcement member having a panel and one or more standoffs extendingfrom the panel, the panel being shaped to conform to at least a portionof the bottom wall of the box so that the panel can be positioned withinthe electrical box adjacent the bottom wall, and the one or morestandoffs extend toward the front face of the box and include at leastone connecting hole configured to receive a fastener of the fixture; anda shroud configured to be connected with the front face of the box. 13.The electrical box assembly according to claim 12, wherein the bottomwall of the electrical box includes a mounting zone having a pluralityof box mounting holes.
 14. The electrical box assembly according toclaim 13, wherein the panel has a plurality of panel mounting holes thatare positioned to align with the box mounting holes such that one boxmounting hole aligns with one panel mounting hole when the panel ispositioned within the electrical box adjacent the bottom wall.
 15. Theelectrical box assembly according to claim 12, wherein the box is formedfrom a moldable non-conductive material.
 16. The electrical box assemblyaccording to claim 15, wherein the moldable non-conductive materialcomprises a plastic material.
 17. The electrical box assembly accordingto claim 16, wherein the plastic material comprises a moldable polymerresin.
 18. The electrical box assembly according to claim 12, whereinthe reinforcement member is formed from a metal or metal alloy.
 19. Theelectrical box assembly according to claim 12, wherein the electricalbox comprises a first mating surface on the open front face and theshroud comprises a corresponding second mating surface, and wherein whenjoined the first and second mating surfaces create a weatherproofengagement.
 20. The electrical box assembly according to claim 12,wherein the one or more standoffs comprise an arm extending from thepanel and a connecting leg substantially perpendicular to the arm andhaving the at least one connecting hole.
 21. The electrical box assemblyaccording to claim 12, wherein the box comprises one or more conduitopenings.
 22. A ceiling fan kit comprising: an electrical box assemblycomprising: an electrical box having a bottom wall and an open frontface; a reinforcement member having a panel and one or more standoffsextending from the panel, the panel being shaped to conform to at leasta portion of the bottom wall of the box so that the panel can bepositioned within the electrical box adjacent the bottom wall, and theone or more standoffs extend toward the front face of the box andinclude at least one connecting hole configured to receive a fastener ofthe fixture; and a ceiling fan assembly having a ceiling fan and aceiling fan mounting bracket.
 23. The ceiling fan kit according to claim22, further comprising a shroud configured to be connected with thefront face of the box.